Mattress structure

ABSTRACT

A bed and mattress structure includes an articulating frame having longitudinally spaced head, seat, thigh, and foot sections. The head, thigh and foot sections are movable relative to each other and relative to the seat section. A deck on the frame supports a user. A mattress is interposed between the deck and the user. The mattress includes a plurality of longitudinally spaced apart, transversely extending air bladders corresponding respectively to the frame sections. A power driver tilts the frame sections to desired tilted positions. An air supply fills each bladder to desired air pressures to support the user. A drive controller controls the power drive for tilting the frame sections to various desired positions. An air supply controller controls the air supply for filling the air bladders to desired air pressures. A hand held controller includes a key pad cooperating with a programmable device to provide signals through a cord in response to inputs from the user. The key pad includes memory set buttons providing the signals when the buttons are activated by the user. The controller controls the power drive and the air supply in response to the signals. The memory set buttons are arranged in order of the frequency of use. A display is mounted on the substrate and selectively indicates the positions of the sections of the articulating frame and the pressures of the air bladders.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of copending application Ser.No. 08/565,409 filed Nov. 30, 1995

BACKGROUND AND SUMMARY OF THE INVENTION

[0002] The present invention relates to bed and mattress structures andparticularly to mattress structures which may be customized forindividual users at the point of sale. The mattress of the presentinvention may be delivered to the user in a variety of forms assembledfrom kits provided at the point of sale to accommodate themusculoskeletal condition of the user. The mattress may also becustomized at the factory or at some assembly location other than thepoint of sale based on a customer's reaction to a test mattress used atthe point of sale, the test mattress comprising a plurality of airbladders arranged under the user with a system for recording airpressures producing the desired support and firmness for the user. Thesebladder air pressures may be converted at the factory to equivalent foamcore structures having the desired support and firmness characteristics.

[0003] It is well known to provide foam support pads or mattresses forsupporting a user reclining on the pad. For example, U.S. Pat. Nos.4,879,776; 5,038,433; 5,077,849; 5,111,542; and 5,172,439, all toFarley, disclose mattress overlays and pads for supporting a user. Inaddition, U.S. Pat. Nos. 4,449,261 to Magnusson and 4,991,244 to Walkerdisclose mattress borders for receiving core mattresses, and U.S. Pat.No. 5,105,488 to Hutchinson et al.; U.S. Pat. No. 4,803,744 to Peck etal.; and U.S. Pat. Nos. 4,424,600 and 4,435,864 to Callaway, disclosesupporting surfaces having selectively adjustable firmness.

[0004] What is needed is a mattress that can be prepared using amattress kit for customizing the mattress either at the point of sale orat a factory using data generated at the point of sale to provide a userwith a mattress having reduced interface pressure while providing theuser with his or her individually desired support and firmnesscharacteristics. The improved mattress should be capable of side-by-sidecustomization when the mattress is sized for use on queen-sized beds andking-sized beds so that two sleeping partners are each provided withtheir individually desired support and firmness characteristics on thesame bed. The improved mattress should also be compatible with anarticulating bed so that the mattress can be moved to a variety ofpositions selected by the user.

[0005] In addition, the improved mattress should be provided withfeatures such as a “warm air release” to warm the extremities of theuser, multiple longitudinal zones that can be controlled to vary thesupport and firmness characteristics perceived by the user, and itshould be provided with a hand held controller having a key padincluding a display that is easy to read to determine the status ofvarious features of the bed, buttons that are located for convenientmanipulation for adjusting various aspects of the bed and mattressstructure, and memory setting capability for matching a desired bed deckposition with desired firmness and support characteristics so that bysimply pressing one button the bed automatically moves to theuser-selected position and the mattress automatically assumes theuser-selected firmness and support characteristics selected for eachzone of the mattress.

[0006] According to the present invention, a plurality of mattressstructure components is provided. The components are arranged forselective assembly of the components to provide a customized mattressstructure at the point of sale to accommodate the musculoskeletalcondition and interface pressure preference of the user. The mattressstructure components include a perimetral frame having a head end foamsection, a foot end foam section, and longitudinally extending side foamsections joining the head and foot foam sections to provide alongitudinally extending foam frame. The foam frame has a centralopening above which the user will rest and the frame sections have uppersurfaces lying generally in the same common plane.

[0007] The mattress structure components additionally include aplurality of cores for filling the central opening. The cores areprovided in a variety of firmness and support characteristics such thatvarious combinations of firmness and support can be provided. Aplurality of toppers cover the frame and the central opening and theselected cores therein. The plurality of toppers include toppers havingvarious firmness and support characteristics and can be made from foamrubber and can include air bladders, water bladders, or bladders forcontaining other fluids.

[0008] In preferred embodiments, the mattress is supported by anarticulating deck having longitudinally spaced head, seat, thigh, andfoot sections. The head, thigh, and foot sections of the illustrativearticulating deck are movable relative to each other. The head, thigh,and foot sections are infinitely adjustable between a generally planarsleeping position and reclining positions to allow the bed to attain anydesired position within the range of movement of the head, thigh, andfoot sections, thus accommodating changes of position of the user on thebed. Preferably, the range of movement of the foot section is limited topositions generally parallel to the seat section and the downward rangeof movement of the thigh section is limited to the sleeping position sothat the feet of the user remain elevated above the torso of the user.

[0009] The mattress is suitable for use with such an articulating deck.The mattress includes a head portion for supporting the scapula and thelumbar of the user, a seat portion for supporting the user's sacrum, athigh portion for supporting the thighs of the user, and a foot portion.Each named mattress portion is associated respectively with the head,seat, thighs, and feet of the person resting on the sleeping surface ofthe bed as well as with the underlying head, seat, thigh, and footsections of the deck.

[0010] The mattress includes a mattress cover having a top mattresscover and a bottom mattress cover attached to the top mattress cover bya perimetral zipper. The top and bottom mattress covers define amattress interior receiving a plurality of mattress structurecomponents. The zipper is positioned so that the bottom cover can beplaced on a surface and used as a template for building the mattresswith a “bottom up” assembly technique placing the components on thebottom of the mattress on top of the bottom cover and building the othercomponents thereon. The zipper is also positioned to facilitate a “topdown” assembly by starting with the top cover and first adding thecomponents on the top of the mattress to the top cover and building theother components thereon.

[0011] The mattress structure components include a frame preferably madefrom a relatively firm foam rubber such as a high resiliency, highdensity urethane foam. The frame is positioned generally along theperimeter of the mattress. Use of a relatively firm foam providessupport characteristics that aid users as they ingress and egress to andfrom an upwardly-facing sleeping surface of the mattress and thatprevent the user from rolling off of the sleeping surface. The frame isformed to include a central opening beneath the sleeping surface andabove which the user will rest.

[0012] A plurality of cores including air bladders, “zone foam”elements, “sculptured foam” shaped from foam blocks, and combinationsthereof are provided for filling the central opening. The cores areselected to customize the firmness, support, and interface pressurecharacteristics to meet the individual desires of each user. Tocustomize the mattress in such a fashion requires considering thecombination of each individual's height, weight, body type, weightdistribution, health conditions, and preferences.

[0013] The preferred method for customizing the mattress is initiatedwhen a potential user completes a questionnaire to aid in the analysisof that user's “sleep profile.” The sleep profile assesses such factorsas the user's general health and sleep habits. A firmness recommendationis computed either in terms of a pressure for various zones of a “testmattress” containing an air bladder or in terms of a foam type anddensity for each zone. In addition, a surface recommendation isestablished based on the user's responses to a surface recommendationquestionnaire.

[0014] Once the surface and hardness recommendations are established,the user lies on a test sleeping surface containing an air bladder thatis pressurized to match the firmness recommendation. Zones of the airbladder are then adjusted to match the preferences of the user and theresulting preferred firmness readings are recorded. An algorithm hasbeen developed that translates the preferred firmness readings into acustomized bed configuration. For example, the preferred firmnessreadings can be translated to establish the foam density that, ifincorporated into a mattress will provide the firmness and supportcharacteristics similar to those provided by the test sleeping surfacehaving the preferred firmness readings.

[0015] Once the customized bed configuration is established, a mattresscan be assembled from a kit at the point of sale containing theplurality of cores for the user to test and verify that the mattressmeets his or her preferences. If the mattress is not satisfactory, itcan be adjusted at the point of sale. Once the user is satisfied, he orshe can immediately take delivery of the completed customized mattressif desired. In the alternative, once the customized bed configuration isestablished, the data describing this configuration can be transmittedto a factory at which the mattress is assembled for delivery to theuser.

[0016] In preferred embodiments, the mattress in accordance with thepresent invention can be sized for a twin bed, a double bed, aqueen-sized bed, or a king-sized bed. When the mattress is sized forqueen- and king-sized beds, both sides of the mattress can beindividually customized if desired to provide the firmness and supportcharacteristics desired by individual sleep partners by customizing thecore and customizing the topper to provide the desired firmness andsupport for each side of the bed. In such a “side-by-side”customization, the core and toppers supporting each user on separatehalves of the mattress are distinct and separate. Having distinct andseparate cores and toppers facilitates this customization while alsoserving to minimize the transmission of motion from one half of themattress to the other when one of the sleeping partners moves.

[0017] As mentioned above, the mattress can be provided with an airbladder having independent zones that are selectively adjustable by theuser to provide varied firmness and support characteristics. If the samemattress is used on a bed having an articulating deck, the mattress canbe provided with a hand held controller for use by the user thatcontrols the adjustment of both the position of the deck and the supportcharacteristics of each bladder zone. In addition, the hand heldcontroller can include a “memory set” feature which allows the user toestablish preferred deck and mattress combination settings.

[0018] For example, the user may desire a first set of supportcharacteristics at each zone of the mattress when the deck is in agenerally planar sleeping position. The user could establish this set ofcharacteristics as the first memory setting. The user may also desire adifferent set of support characteristics at each zone of the mattresswhen the deck is positioned in a reclining position away from thegenerally planar sleeping position. If the user establishes this secondset of characteristics as the second memory setting, the user canautomatically move the bed and mattress structure to either of the firstor second set of characteristics by simply pressing a button. Of course,even with these memory settings established, the user can move the bedand mattress to other positions as desired.

[0019] In addition, the mattress can be provided with combinations ofair bladders, zone foam elements, and sculptured foam to produce a“combination mattress.” For example, the mattress can be provided havingan air bladder supporting the scapula, foam supporting the lumbar, anair bladder in the seat portion supporting the sacrum, and foamsupporting the thighs and legs. If desired, the air bladders can be influid communication so that they inflate and deflate at the same timesand to the same pressures or the air bladders can be independent of oneanother and independently controlled by the user so that they user canestablish different characteristics of support and firmness for each ofthe scapula and the sacrum.

[0020] It is therefore an object of the present invention is to providea unique mattress structure which may be customized for individual useto provide the optimum health and comfort characteristics for the userand also to provide, for use with such a mattress, an articulatingframe. In some embodiments of the present invention, the mattresscomprises air cores or air bladders arranged in longitudinally spacedzones and a control system for controlling the firmness of the zones ofthe mattress with respect to various positions of the articulating frameso that the user can customize the mattress for his or her preferredfirmness and support characteristics at any angular position of thedeck. In other embodiments, the mattress comprises a sculptured foamcore or a plurality of longitudinally spaced foam zone cores or blocksselected to match the musculoskeletal condition of the user.

[0021] The mattress of the present invention may be assembled at thepoint of sale to comprise a foam perimetral frame defining alongitudinally extending central opening above which the user will restand into which various core structures from a supply of different corestructures may be selectively placed. For example, the central space maybe filled with an air bladder core, the pressure of which may becontrolled and such air cores may have one zone throughout the length ofthe space or a plurality of longitudinally spaced air zones or airbladders throughout the length of the space, for example, one zone forthe head and shoulder portion supporting the scapula and the lumbar, onezone for the seat portion supporting the sacrum, one zone for the thighportion, and one zone for the foot portion. In other cases, the centralspace may be filled with a sculptured foam core or a plurality of foamzone cores or blocks which are selected from a variety of zone foamblocks having various characteristics of support and firmness. The framewith the filled core opening may be covered with one or more toppers,each of which may be selectively picked from a stock of toppers to givethe user a desired comfort.

[0022] It is another object of the present invention, therefore, toprovide, at the point of sale where the user will be available, amodular kit for constructing a mattress which has the firmness and bodysupport characteristics best suited for the user. The present inventioncontemplates that a plurality of cores of various characteristics willbe stocked along with the foam frames and plurality of toppers. Eachmattress may be customized by selecting components from the stock ofparts at the point of sale. For ease of transportation, the selectedassembly may be given to the user at the point of sale inknocked-down-assembly or KDA form for transportation home andreassembly.

[0023] It is another object of the present invention to provide, incombination with such a mattress, an articulating frame of the typetypically referred to as a hospital bed frame. Such articulating frameshave a movable head and shoulder section which includes the lumbarsection, a fixed seat section, a movable thigh section and a movablefoot section. It is well known that the head and shoulder section tiltsupwardly from the horizontal position to an upper position and selectedpoints therebetween. The seat section is typically fixed to stayhorizontal. The thigh section typically tilts upwardly from the seatsection and the foot section typically remains generally parallel to theseat section. These head and shoulder, seat, thigh and foot sections arelongitudinally spaced on an articulating frame. It is also well knownthat these articulating frame sections may be selectively moved by allsorts of drive means including elective motor driven systems, hydraulicsystems or pneumatic systems. It will be appreciated that, in accordancewith the present invention, various mechanical and electromechanicalactuators and drivers may be used to raise and lower the intermediateframe on the base frame as well as to raise and lower individual decksections relative to the intermediate frame.

[0024] It is well known in the hospital bed art that electric drivemotors with various types of transmission elements including lead screwdrives and various types of mechanical linkages may be used to causerelative movement of portions of hospital beds. It is also well known touse pneumatic actuators to actuate and/or move individual portions ofhospital beds. As a result, the terms “means for raising and lowering”in the specification and in the claims, therefore, are intended to coverall types of mechanical, electromechanical, hydraulic and pneumaticmechanisms, including manual cranking mechanisms of all types, forraising and lowering portions of the hospital bed of the presentinvention. It is another object of the present invention to provide acontrol system for an articulating frame with the control systemcomprising a computer and software designed to preselect air bladderfirmness to accommodate various articulated positions of the framesections.

[0025] Still another object of the present invention is to provide amethod for selecting mattress structure components to provide acustomized foam mattress structure to accommodate the musculoskeletalcondition of the user comprising the steps of providing a plurality ofmattress structure components arranged for selective assembly of thecomponents, the components comprising a plurality of foam cores forfilling a longitudinally extending central opening in a mattress, thefoam cores having a variety of shapes and support and firmnesscharacteristics from which to select a desired assembly. A test mattressis also provided having a similar longitudinally extending centralopening filled with a plurality of longitudinally spaced apart airbladders extending transversely across the central opening and an airsupply for selectively filling each air bladder to various pressures. Auser is placed above the central opening supported on the plurality ofair bladders. The air pressure in each bladder is adjusted to a selectedpressure to provide the support and firmness desired by the user. Then,using the air pressure established for each bladder, an equivalent foamcore is selected to have the desired support and firmnesscharacteristics corresponding to the air pressure readings. The selectedequivalent foam core is placed in the central opening to provide thecustomized mattress. The selected equivalent foam core may comprise aplurality of transversely extending zone foam blocks to occupy thepositions, respectively, of the air bladders in the test mattress witheach zone foam block having firmness and support characteristicscorresponding to the selectively determined air pressure of itsassociated air bladder. Further, the selected equivalent foam core maycomprise a sculptured foam core having a width and a length conforminglyto fit into the central opening with transversely extending,longitudinally spaced sections of the sculptured core being shaped andformed to provide firmness and support characteristics corresponding tothe selectively determined air pressures of their respective associatedair bladders in the test mattress. It will be appreciated that softwarehaving appropriate algorithms may be used for making the selection offoam cores to match the selected air pressure.

[0026] Another object of the present invention is to provide a controlsystem for such a bed and mattress structure with the bed having such anarticulating deck with movable sections. The control system comprisesmeans for controlling the drive means for tilting the deck sections tovarious desired positions, means for controlling the air supply forfilling the air bladders to desired air pressures, and a microprocessorand software for controlling the drive control means and the air supplycontrol means to establish the desired frame positions and correspondingbladder pressures. The software of the present invention may beprogrammed to permit the user to preselect desired air pressures in thebladders to correspond to various positions of the deck sections. Thesoftware may also be programmed to permit the user to preselect andstore in the control system various desired frame section positions andcorresponding pressures. The control system of the present invention mayinclude a receiving control unit mounted on the bed structure and aportable, hand-held remote transmitting control unit for actuation bythe user.

[0027] Another object of the present invention is to provide a mattressstructure comprising an elongated sculptured foam mattress core having ahead end, foot end, longitudinally extending sides, a bottom surface andan upper surface above which the user rests. This sculptured core haslongitudinally spaced apart, transversely extending sections to beunder, respectively, the head and shoulder, seat, thigh and feet of theuser. At least some of the core sections are sculptured by removal offoam by transversely extending cuts from the upper surface of the coreto provide sections having desired firmness and support characteristics.These transversely extending cuts may illustratively extend between thesides of the core to provide transversely extending grooves havingselected depths and longitudinal spacing therebetween to provideupwardly and transversely extending ridges for supporting the user, eachof the ridges having support and firmness characteristics determined bythe firmness of the foam and the longitudinal and depth dimensions ofthe grooves. Such a core may also be provided with longitudinallyspaced, transversely and upwardly extending cuts in the lower surface toaccommodate the tilting movement of the mattress by the bed frame uponwhich the mattress is placed, the lower surface cuts beinglongitudinally spaced to accommodate tilting movement of the head andshoulder, seat, thigh and feet section of the core. A foam frame may beplaced about such a sculptured core in accordance with the presentinvention. At least one foam topper may be placed above the frame andcore upper surface with the toppers selected to have desired support andfirmness characteristics. In addition, a foam and fiber pillow top (foamcovered with a fiber fabric) also selected to have desired support andfirmness characteristics may be placed on top of the topper.

[0028] Another object of the present invention is to provide a mattressstructure comprising a bottom layer of material providing an upwardlyfacing rectangular platform upon which the mattress rests and definingthe ends and sides of the mattress, a perimetral rectangular framecomprising foam side and end sections to provide a longitudinallyextending central opening above which the user will rest, a corestructure for filling the central opening, at least one foam toppercovering the frame and the core structure, and a mattress coverenclosing the bottom layer of material, frame, core structure andtopper. In accordance with the present invention, the mattress cover isprovided with an opening adjacent the bottom of the mattress and throughwhich the mattress is designed for either bottom-up or top-down assemblythrough the mattress cover opening. Top-down assembly includes, forexample, sequentially placing the topper, frame, core structure andbottom layer of material to build the mattress structure, whilebottom-up assembly includes sequentially placing the bottom cover,frame, core structure, and topper to build up the mattress structure.The mattress cover opening may be defined by a perimetral zipper closurealong the perimeter of the bottom of the mattress.

[0029] Another object is to provide such a mattress with a double wideframe providing first and second longitudinally extending openings abovewhich separate users will rest. A first core structure is provided forfilling the first opening and a second core structure is provided forfilling the second opening. The first and second core structures havefirmness and support characteristics separately customized for theirseparate users in accordance with this invention.

[0030] Still another object of the present invention is to provide sucha mattress structure comprising an air heater arrangement disposed inthe mattress to provide a “warm air release,” preferably to warm theextremities of the user. The top cover of the mattress can be formed toinclude an enclosed channel receiving air from a source of compressedair. The enclosed channel is preferably made from a light weight and airimpermeable material so that air is directed along the length of thechannel. The material is formed to include small openings that direct asmall volume of air from the channel across the surface of the mattress.This “cool air release” can improve the comfort of the user.

[0031] In addition, an air heater is interposed between the source ofcompressed air and the channel so that heated air can be supplied to thechannel. The air heater can be selectively operated so that when the airheater is operating, the released air is warm, the “warm air release”warming the user. Preferably, the warm air is directed to warm theextremities of the user. In preferred embodiments, a valve is positionedbetween the source of compressed air and the channel so that the channelcan be operated or not operated at the discretion of the user.

[0032] Additional objects, features, and advantages of the inventionwill become apparent to those skilled in the art upon consideration ofthe following detailed description of the preferred embodimentsexemplifying the best mode of carrying out the invention as presentlyperceived.

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The detailed description particularly refers to the accompanyingfigures in which:

[0034]FIG. 1(a) is an exploded perspective view of a mattress inaccordance with the present invention showing a bottom cover positionedbeneath a foam bottom and a frame, a plurality of cores receivable abovethe foam bottom in a central opening formed in the frame, the pluralityof cores including either a sculptured foam core, transversely extendingzone foam blocks, an air bladder, or a combination thereof, the mattressalso including a foam topper positioned to lie above the frame and thecore, a top cover surrounding the topper, the frame, and the foambottom, the top cover including a zipper half engaging a zipper half onthe bottom cover to attach the top cover thereto, and a pillow topattached to the top of the top cover;

[0035]FIG. 1(b) is a view similar to FIG. 1(a) showing a mattressincluding a core having a combination of zone foam blocks and airbladders with zone foam blocks positioned to support the lumbar regionof the back of the user and the thighs and legs of the user and airbladders positioned to support other portions of the user;

[0036]FIG. 1(c) is a view similar to FIG. 1(b) showing a mattressincluding a core having a combination of zone foam blocks and airbladders with air bladders positioned to support the lumbar region ofthe back of the user and the thighs of the user and zone foam blockspositioned to support other portions of the user;

[0037]FIG. 2 is an exploded perspective view of a king-sized mattresssimilar to the mattress of FIG. 1(a) showing the bottom cover, the foambottom, the frame, a foam divider received in the central opening of theframe to divide the central opening into two equally-sized sideopenings, the plurality of cores being alternatively receivable in thetwo side openings, the king-sized bed also including the topper, the topcover, and the pillow top;

[0038]FIG. 3 is an exploded perspective view of a mattress and bedstricture in accordance with the present invention including afoundation and the mattress and showing the mattress positioned to lieabove the foundation and a pillow top positioned to lie above themattress, the mattress being attached to the foundation by a pair ofelongated hook and loop type fasteners attached to the foundation and tothe mattress at a foot end of the mattress to allow relativelongitudinal motion at a head end of the mattress and foundation duringarticulation of the mattress and foundation, the pillow top beingconnected to the top cover of the mattress by a pair of elongated hookand loop type fasteners attached to a top cover of the mattress andattached to the pillow top, the pillow top also being coupled to themattress by a pair of elongated straps fixed to the head end of the topcover of the mattress to form longitudinal loops and short straps whichfeed through the loops and are attached to the pillow top so that thehead end of the pillow top can slide longitudinally relative to the topcover of the mattress while remaining generally fixed in the transversedirection relative to the pillow top;

[0039]FIG. 4 is a diagrammatic view of an articulating deck for carryingthe mattress in accordance with the present invention showing the deckmoved to a position other than a generally planar sleeping position;

[0040]FIG. 5 is a diagrammatic sectional view taken along line 5-5 ofFIG. 1(a) showing a sculptured foam core resting on an articulating deckof a bed, the deck being in a generally planar sleeping position;

[0041]FIG. 6 is a view similar to FIG. 5 showing the deck in a positionhaving the head section lifted to an upward raised position, the thighsection lifted slightly to an upward raised position, and the footsection elevated above and generally parallel to the seat section, cutsformed in the sculptured foam core on the surface opposite the foldsallowing the sculptured foam core to generally conform to the shape ofthe deck;

[0042]FIG. 7 is a perspective view of the frame and the foam divider ofFIG. 2 showing the frame and the foam divider rail moved by anarticulating deck (not shown) to a position other than the generallyplanar sleeping position, cuts formed in side foam sections of the frameon the surface opposite the bends and cuts formed in the foam dividerrail on the surface opposite the bends allowing the frame and foamdivider rail to generally conform to the shape of the deck;

[0043]FIG. 8(a) is a diagrammatic bottom view of a “four-zone” airbladder and pressurized air supply with portions broken away showing thepockets formed in the air bladder by I-beams (not shown) attached to theinterior of the air bladder, and showing each I-beam having first andsecond transverse ends, the first and second ends of a first set ofI-beams being spaced-apart from the edge of the air bladder to formopenings allowing fluid communication between pockets, and adiagrammatic manifold of the pressurized air supply;

[0044]FIG. 8(b) is a view similar to FIG. 8(a) of a four-zone airbladder in which zones of the air bladder which are not adjacent to oneanother are in fluid communication showing an upper back zone in fluidcommunication with a seat zone through a first tube positioned outsideof an internal region of the air bladder and a lower back zone in fluidcommunication with a foot zone through a second tube positioned outsideof an internal region of the air bladder;

[0045]FIG. 9 is a diagrammatic illustration of a sectional view takenalong line 9-9 of FIG. 8(a) showing the four-zone air bladder havingpockets separated by I-beams with the selected I-beams defining thezones of the air bladder, the ends of a second set of I-beams sealinglyengaging the edge of the air bladder to separate pockets adjacent to theI-beams to form separate and independently inflatable and deflatablezones of the air bladder;

[0046]FIG. 10 is a schematic view of a valve manifold for a one-zone airbladder showing a compressed air line, an exhaust line, an air line influid communication with the interior region of the air bladder, and atransducer for transducing a pressure measurement to an electronicoutput signal;

[0047]FIG. 11 is a diagrammatic sectional view of the bladder of FIG.8(a) showing an interior region of the partially inflated air bladderincluding I-beams of generally uniform height with one I-beam beingsignificantly taller than the remaining I-beams;

[0048]FIG. 12 is a view similar to FIG. 11 showing the air bladder fullyinflated so that the air bladder adjacent to the pockets defined by thesignificantly taller I-beam project above the air bladder adjacent tothe other pockets so that the mattress adjacent to the projectingpockets provides a user with additional support and firmness;

[0049]FIG. 13 is a sectional view taken along line 13-13 of FIG. 8(a)showing an interior region of the partially inflated air bladderincluding I-beams of generally uniform height with two I-beams beingsignificantly taller than the remaining I-beams;

[0050]FIG. 14 is a view similar to FIG. 13 showing the air bladder fullyinflated so that the air bladder adjacent to the pockets defined by thesignificantly taller I-bemas project above the air bladder adjacent tothe other pockets so that the mattress adjacent to the projectingpockets provides a user with additional support and firmness;

[0051]FIG. 15 is a view similar to FIG. 9 showing the air bladder havinga plurality of significantly taller I-beams so that the air bladderadjacent to pockets adjacent to the lumbar region of the user, pocketsadjacent to the thigh of the user, and pockets adjacent to the heel ofthe user project above the air bladder adjacent to the other pockets toprovide a user with additional support and firmness near portions of themattress adjacent to the projecting pockets and to provide additionalpressure relief to the heels of the user;

[0052]FIG. 16 is a view of the mattress of FIGS. 1(a) and 2 showing anair supply providing pressurized air to an air bladder inside of themattress and to an enclosed channel formed along the perimeter of theupwardly-facing sleeping surface of the mattress and an air heaterinterposed between the air supply and the channel to heat the airreceived by the channel, the material enclosing the channel being formedto include small openings that direct a small volume of air from thechannel across the sleeping surface to warm or cool the user;

[0053]FIG. 17 is a perspective view of an arm rest in accordance withthe present invention showing the foam interior of the arm rest;

[0054]FIG. 18 is a sectional view of taken along line 18-18 of FIG. 17showing a cover surrounding the arm rest and showing a cup (in phantom)received in a cup holder formed in the arm rest;

[0055]FIG. 19 is a view similar to FIG. 18 showing a bed having anarticulated deck moved to a position away from the generally planarsleeping position, a mattress received on the deck, and the arm rest ina first orientation;

[0056]FIG. 20 is a view similar to FIG. 19 showing the deck moved to adifferent position away from the generally planar sleeping position, themattress on the deck, and the arm rest in a second orientation;

[0057]FIG. 21 is a perspective view of the hand held controller of FIG.16 for controlling the positions of the articulating portions of thearticulating deck of the bed, controlling the pressure of air in thefour zones of the bladder, and for pre-setting in memory air pressuresselected by the user corresponding to deck positions selected by theuser so that by pressing a single button the deck will adjust to thepreselected position and the bladder will adjust pressures in the fourzones to the preselected pressures; and

[0058]FIG. 22 is a plan view of a portion of the hand held controller ofFIG. 21 showing the indicia on the hand held controller and showing “bedposition buttons” on a first end, the buttons being arranged in a“use-frequency arrangement” having the most frequently used buttonspositioned to lie adjacent to the first end, the least frequently usedbuttons positioned to lie adjacent to the second end which is oppositethe first end, and the remaining buttons positioned to lie therebetweenarranged in order of the frequency of use with the more frequently usedbuttons being positioned closer to the first end than the lessfrequently used buttons;

[0059]FIG. 23 is a schematic block diagram illustrating the electricalcomponents of a control system for controlling features of the bed andmattress structure in accordance with the present invention; and

[0060] FIGS. 24A-24L are flow charts illustrating steps performed by thecontrol system for manipulating the bed and mattress structure inresponse to inputs made by the user by way of the hand held controller.

DETAILED DESCRIPTION OF THE DRAWINGS

[0061] A bed and mattress structure 50 includes a mattress 52 inaccordance with the present invention as illustratively shown in FIGS.1(a) and 2. As used in this description, the phrase “head end 46” willbe used to denote the end of any referred-to object that is positionedto lie nearest head end 46 of bed and mattress structure 50. Likewise,the phrase “foot end 48” will be used to denote the end of anyreferred-to object that is positioned to lie nearest foot end 48 of bedand mattress structure 50.

[0062] Mattress 52 includes a bottom cover 54 having a perimeter edge 56and a first zipper half 58 attached to perimeter edge 56 as shown inFIGS. 1(a) and 2. Mattress 52 also includes a top cover 60 whichcooperates with bottom cover 54 to define a mattress interior 72.

[0063] Top cover 60 includes an upwardly-facing top portion 62 and adownwardly-extending side portion 66 as shown in FIGS. 1(a) and 2. Sideportion 66 includes a bottom edge 68 and a second zipper half 64attached to bottom edge 68, second zipper half 64 attaching to firstzipper half 58 to form zipper 70 which connects top cover 60 and bottomcover 54.

[0064] Although zipper 70 is positioned to lie adjacent to bottom edge68, a bottom cover could be provided having an upwardly-extending sideportion 67 as shown in FIGS. 1(b) and 1(c) defining a mattress side andthe second zipper half could be attached to side portion 67 of thebottom cover so that zipper 70 could be positioned along the mattressside or the upper perimetral edge of mattress 52. Zipper 70 cantherefore be positioned to lie adjacent to bottom edge 68 or at anyposition along the mattress side, which in preferred mattress 52includes side portion 66, without exceeding the scope of the inventionas presently perceived. However, positioning zipper 70 adjacent bottomedge 68 provides certain assembly related advantages described belowwhile also improving the appearance of mattress 52 by allowing zipper 70to be easily hidden.

[0065] A frame 74 having a head end foam section 76, a foot end foamsection 78, and longitudinally extending side foam sections 80 joiningthe head end and foot end foam sections 76, 78 is received in mattressinterior 72 as shown in FIGS. 1(a) and 2. In preferred embodiments,frame 74 is formed with rounded corners to enhance the appearance ofmattress 52. In addition, joints 83 connect head end foam section 76 toside foam sections 80 and foot end foam section 78 to side foam sections80. Joints 83 are preferably lap joints having portions of head end andfoot end foam sections 76, 78 overlapping and fastened to respectiveportions of side foam sections 80. Forming joints 83 in this mannerresults in additional support provided to head end foam section 76 whenmattress 52 slides past head end 46 of foundation 120 duringarticulation of deck 138.

[0066] Head end, foot end, and side foam sections 76, 78, 80 of frame 74cooperate to define a central opening 82 as shown best in FIGS. 1(a) and2 above which a user (not shown) will rest. A foam bottom 84 is receivedin central opening 82 and foam bottom 84 and frame 74 lay against bottomcover 54. A topper 86 rests against the top of frame 74 and abovecentral opening 82 to engage top portion 62 of top cover 60. A core orcore structure 88 is received in central opening 82 and is positioned tolie between foam bottom 84 and topper 86. Having topper 86 sized tocover both frame 74 and core 88 minimizes the ability of the user toperceive the interface between frame 74 and core 88.

[0067] In preferred embodiments, a pillow top 90 is attached to the topof top portion 62 of top cover 60 and is positioned to lie outside ofmattress interior 72 as shown in FIGS. 1(a) and 2 to define a sleepingsurface 122 on which a user will rest. Top cover 60 is preferably madefrom a material having a low coefficient of friction such as apolypropylene anti-shear material to allow for the sliding movement ofpillow top 90 relative to top cover 60 near head end 46 of mattress 52.In addition, top cover 60 should be somewhat elastic so that the usercan “sink into” mattress 52 allowing mattress 52 to conform to theuser's shape, thereby relieving interface pressure.

[0068] Pillow top 90 typically includes a foam pad (not shown) coveredby fabric and adorned, for example, by buttons 124, ornamentalstitching, or the like to enhance the appearance of pillow top 90.Pillow top 90 can be attached to top cover 60 using any suitable methodsuch as by a zipper (not shown), adhesive (not shown), straps (notshown), or even sewing pillow top 90 to top cover 60. However, asdescribed below with reference to FIG. 3, pillow top 90 is preferablyattached to top cover 60 using hook and loop type fasteners so thatpillow top 90 is easily removable and replaceable. Mattress 52 canalternatively be provided without pillow top 90, in which case theupwardly-facing surface of top portion 62 of top cover 60 serves assleeping surface 122.

[0069] Core 88 can alternatively include either a set of zone foamblocks 92, a sculptured foam core 94, an air bladder 96, or acombination thereof as shown in FIGS. 1(a)-(c) and 2. In preferredembodiments, frame 74, foam bottom 84, topper 86, zone foam blocks 92,sculptured foam core 94, and an interior portion (not shown) of pillowtop 90 may be made from a foam rubber such as urethane foam. Thefirmness and support characteristics of the foam rubber can be varied inaccordance with the desires of the user of mattress 52. The firmness andsupport characteristics of the foam rubber is varied by varying eitherthe density of the foam or the shape of the outer surfaces of the foam.

[0070] Although urethane foam is the preferred material for thesecomponents, any material providing support and firmness characteristicssimilar to those provided by foam rubber can be used without exceedingthe scope of the invention as presently perceived. For example, topper86 can be made from latex foam or urethane foam, or in the alternativeit can include an air bladder, a water bladder, or a bladder for otherfluids without exceeding the scope of the invention as presentlyperceived.

[0071] Mattress 52 typically rests on a foundation 120, as shown in FIG.3, such as box springs, a stationary deck of a bed, an articulating deckof a bed, or the like. Mattress can also rest on a floor or any othergenerally planar, upwardly facing surface without exceeding the scope ofthe invention as presently perceived.

[0072] In preferred embodiments, foundation 120 and the underside ofbottom cover 54 are provided with elongated mating portions of hook andloop type fasteners 164 so that mattress 52 is removably attached tofoundation 120 as shown in FIG. 3. Fasteners 164 prevent lateralmovement of mattress 52 relative to foundation 120. However, fasteners164 are preferably spaced apart from head end 46 of bed and mattressstructure 50 so that head end 46 of mattress 52 can slide longitudinallyrelative to head end 46 of foundation 120 as described below.

[0073] In addition, the underside of pillow top 90 and the upper side oftop portion 62 of top cover 60 of mattress 52 are both provided withelongated mating portions of hook and loop type fasteners 168 as shownin FIG. 3 so that pillow top 90 is removably attached to mattress 52.Mattress 52 is also provided with a pair of longitudinally extendinglong loops 170 and pillow top 90 is provided with a pair of transverselyextending short loops 172. Each short loop 172 includes a first end 174that is fixed to pillow top 90 and a second end 176 that is attached topillow top 90 using hook and loop type fasteners 178. Second end 176 ofeach short loop 172 is received by one of long loops 170 respectively sothat short loops 172 cooperate with long loops 170 to prevent transversemovement of pillow top 90 relative to mattress 52 while allowing thelongitudinal sliding of pillow top 90 relative to mattress 52 duringarticulation of deck 138.

[0074] As described above, mattress 52 is configured for use on bothstationary, generally planar, and upwardly facing surfaces on whichmattress 52 rests during use by a user, as well as on a bed, table, orother device (not shown) having an articulating deck 138 as showndiagrammatically in FIG. 4. Illustrative articulating deck 138 includesa head section 144, a seat section 146, a thigh section 148, and a footsection 150. A light (not shown) or other illuminating device can beprovided having an arm (not shown) or extending bracket attached to headsection 144 so that the light extends to a position illuminatingmattress 52. By attaching the arm to head section, the relative positionof user's head and the light will remain generally fixed.

[0075] Typically, seat section 146 of deck 138 is fixed relative to thebed having a generally horizontal upwardly-facing surface carryingmattress 52 and head, thigh, and foot sections 144, 148, 150 are movablewith respect to the bed (not shown) and with respect to each other tomove mattress 52 so that the position of mattress 52 and the position ofthe user on top of mattress 52 changes. Drivers for moving head, thigh,and foot sections 144, 148, 150 are diagrammatically indicated by arrows152 in FIG. 4. In the preferred articulating deck 138, foot section 150is movable only to positions in which foot section 150 is generallyparallel to seat section 146. In addition, the movement of preferredthigh section 148 is limited to positions between the generallyhorizontal sleeping position and positions upwardly from the sleepingposition so that the feet of the user (not shown) remain generallyvertically even with or elevated above the torso of the user.

[0076] It will be appreciated that various mechanical andelectromechanical actuators and drivers may be used to raise and lowerindividual deck sections 144, 146, 148, 150 relative to the bed as shownin FIGS. 4-5. It is well known in the hospital bed art that electricdrive motors with various types of transmission elements including leadscrew drives and various types of mechanical linkages may be used tocause relative movement of portions of hospital beds. It is also wellknown to use pneumatic actuators including various types of air bladderspowered by pressurized air to actuate and/or move individual portions ofhospital beds. The terms “means for raising or lowering” in thespecification and in the claims, therefore, are intended to cover alltypes of mechanical, electromechanical, hydraulic, and pneumaticmechanisms, including manual cranking mechanisms of all types, forraising and lowering portions of chair bed 50 of the present invention.

[0077] As indicated above, mattress 52 is attached to foundation 120 andpillow top 90 is attached to mattress 52 to allow sliding movement ofhead end 46 of mattress 52 relative to foundation 120 and of pillow top90 relative to mattress 52. It will be apparent to those skilled in theart, that fixing one end of mattress 52 and pillow top 90 and thenmoving articulating deck 138 will cause shear forces between mattress 52and foundation 120 and between pillow top 90 and mattress 52. Connectingmattress 52 to foundation 120 and pillow top 90 to mattress 52 asdescribed above with respect to FIG. 3 will alleviate the shear forcesby allowing head end 46 of mattress 52 and pillow top 90 to slidelongitudinally relative to foundation 120 and relative to each other.

[0078] As described above, core 88 can include zone foam blocks 92. Atypical set of zone foam blocks 92 found in mattress 52 includes aplurality of transversely extending zone foam blocks 92 thatlongitudinally abut one another. If mattress 52 is for use in a singlebed as shown in FIG. 1(a) so that central opening 82 is a first width110, each block 92 typically extends the full width 110 of centralopening 82 to engage opposing side foam sections 80. Typically theplurality of zone foam blocks 92 fills the entire central opening 82 sothat a first of blocks 92 engages head end foam section 76, a last ofzone foam blocks 92 engages foot end foam section 78, and zone foamblocks 92 therebetween engage one another.

[0079] If the mattress is for use in a queen-sized bed (not shown),central opening 82 is a second width and each block 92 typically extendsonly one-half of the second width. In such instance, core 88 canalternatively include side-by-side combinations including a set of zonefoam blocks 92, sculptured foam core 94, and air bladder 96. Forexample, sculptured foam core 94 can be received in opening 82 engagingone of side foam sections 80 and zone foam blocks 92 can be received inopening 82 engaging sculptured foam core 94 on one side and the other ofside foam sections 80.

[0080] For another example, central opening 82 can receive side-by-sideleft and right sets of zone foam blocks 92. A first of the zone foamblocks 92 of the left set of zone foam blocks 92 engages head end foamsection 76, a last of the zone foam blocks 92 of the left set of zonefoam blocks engages foot end foam section 78, and each zone foam block92 of the left set of zone foam blocks 92 engages one of side foamsections 80. A first of the zone foam blocks 92 of the right set of zonefoam blocks 92 also engages head end foam section 76, a last of the zonefoam blocks 92 of the right set of zone foam blocks engages foot endfoam section 78, and each zone foam block 92 of the right set of zonefoam blocks 92 engages the other of side foam sections 80. In addition,zone foam blocks 92 of the left set of zone foam blocks engage zone foamblocks 92 of the right set of zone foam blocks 92. Thus, in aqueen-sized bed zone foam blocks 92 abut one another longitudinally andside-by-side.

[0081] If mattress 52 is for use in a king-sized bed as shown in FIG. 2,central opening 82 is a third width 112 and each block 92 typicallyextends less than one-half of the full width 112 of central opening 82.In such an instance, core 88 can additionally include a foam dividerrail 114. Foam divider rail 114 divides central opening 82 into a firstside opening 116 and a second side opening 118.

[0082] Preferably, first and second side openings 116, 118 have equalwidths, and preferably foam divider rail 114 is sized so that the widthsof first and second side openings 116, 118 are the same as first width110 as shown in FIG. 2. Thus, blocks 92, sculptured foam core 94, andair bladder 96 can interchangeably fit in each of opening 82 of a singleor twin bed as shown in FIG. 1(a) and first and second side openings116, 118 and engage one of side rails 80 and foam divider rail 114 asshown in FIG. 2.

[0083] First opening 116 can receive any of zone foam blocks 92,sculptured foam core 94, and air bladder 96 and second opening 118 canreceive any of the zone foam blocks 92, sculptured foam core 94, and airbladder 96 as shown in FIG. 2. The selection of pieces of core 88received by first opening 116 is independent of the selection of piecesof core 88 of second opening 118, so that core 88 for a mattress for usewith a king-sized bed can include foam divider rail 114, zone foamblocks 92, sculptured foam core 94, air bladder 96, or a combinationthereof.

[0084] For example, if core 88 includes two sets of zone foam blocks 92as described above for a queen-sized mattress, each block 92 will extendthe full width of the respective first or second opening 116, 118 toengage foam divider rail 114 and opposing side foam section 80.Typically each set of zone foam blocks 92 fills the entire first orsecond opening 116, 118 so that a first of blocks 92 engages head endfoam section 76, foam divider rail 114, and one of the side foamsections 80, a last of zone foam blocks 92 engages foot end foam section78, foam divider rail 114, and the same of the side foam sections 80,and blocks 92 therebetween engage one another, foam divider rail 114,and the same of the side foam sections 80.

[0085] Each zone foam block is preferably provided with an anti-shearcoating so that each zone foam block 92 can move in a vertical directionindependently of adjacent zone foam blocks 92 and independently of frame74. The anti-shear coating can be a coating formed on or applied to zonefoam blocks 92 as well as a sleeve 98 having an interior 100 receivingzone foam block 92 as shown in FIGS. 1(a) and 2. Sleeve 98 is preferablymade from a material having a low coefficient of friction such as“parachute material” or nylon.

[0086] The firmness of zone foam blocks 92 can vary from zone foam block92 to zone foam block 92. Preferably, the firmness ranges approximatelybetween an average indention load deflection (ILD) of 15 to 98.Preferred zone foam blocks 92 are provided with ribbed upper and lowersurfaces as shown in FIGS. 1(a)-(c) and 2. Ribs on the surfaces resultin less force being required to compress zone foam blocks 92 than wouldbe required without the ribs. This means that even when little weight isapplied to zone foam blocks 92, blocks 92 will compress and contour touser's shape, thereby reducing interface pressures, and essentiallyreducing the ILD so that the ILD can be “fine-tuned” by the addition ofribs.

[0087] As described above, core 88 can also include sculptured foam core94 as shown in FIGS. 1(a), and 2-4. Sculptured foam core 94 is typicallya unitary piece of foam of uniform firmness that has been sculptured toa desired shape. However, sculptured foam core 94 can be formed from apiece of foam having firmness that varies along its length or across itswidth without exceeding the scope of the invention as presentlyperceived.

[0088] Sculptured foam core 94 is formed to include transverselyextending troughs 130 along a top surface 132 of sculptured foam core 94as well as transversely extending cuts 134 extending inwardly from bothtop surface 132 and a bottom surface 136 of sculptured foam core 94, asshown best is FIGS. 5 and 6 which show sculptured foam core 94 restingon a diagrammatic articulating deck 138 of a bed (not shown). Each cut134 includes a transversely-extending slit 140 extending inwardly fromthe respective surface 132, 136 and terminating in atransversely-extending cylindrical opening 142.

[0089] As described above, each of the head, thigh, and foot sections144, 148, 150 of articulating deck 138 typically move relative to seatsection 146, relative to one another, and relative to the bed as shownin FIGS. 5 and 6. Portions of sculptured foam core 94 adjacent to eachof sections 144, 146, 148, 150 are configured to move with eachrespective section 144, 146, 148, 150. Slits 140 allow for foldingmovement of sculptured foam core 94 in a direction inwardly away fromslits 140 as shown, for example, in FIG. 6, and openings 142 prevent theinadvertent tearing of sculptured foam core 94 when sculptured foam core94 is folded.

[0090] Cuts 134 are positioned so that at least one of cuts 134 liesgenerally between the head and seat sections 144, 146, at least one ofcuts 134 lies generally between the seat and thigh sections 146, 148,and at least one of cuts 134 lies generally between the thigh and footsections 148, 150 as shown in FIGS. 5 and 6. In preferred embodiments,sculptured foam core 94 is provided with a plurality of cuts 134 at eachposition as shown best in FIGS. 5 and 6 so that the above holds truewhen sculptured foam core 94 is used with a variety of beds havingarticulating decks, the longitudinal lengths of the head, seat, thigh,and foot sections 144, 146, 148, 150 of which may vary from bed to bed.

[0091] As mentioned above, sculptured foam core 94 is also provided withtransversely extending troughs 130 formed on top surface 132 shown bestin FIGS. 5 and 6. Troughs 130 can be positioned to facilitate thefolding of sculptured foam core 94 as shown in FIG. 6 by providingadditional space for the surface 132, 136 opposite cuts 134 to compressupon itself. However, troughs 130 are not necessary for the portions ofsculptured foam core 94 to move with the head, seat, thigh, and footsections 144, 146, 148, 150 or articulating deck 138.

[0092] Each trough 130 is formed to include a depth 160 and a width 162as shown best in FIGS. 5 and 6, and both of depth 160 and width 162 canbe varied to vary the characteristics of support and firmness exhibitedby sculptured foam core 94 adjacent to troughs 130. For example, byincreasing depth 160 of troughs 130, sculptured foam core 94 adjacent totroughs 130 provides the user (not shown) with support and firmnesscharacteristics that would be expected from a non-sculptured foammattress having foam that is less firm than the foam comprisingsculptured foam core 94. Likewise, by increasing width 162 of troughs130, sculptured foam core 94 adjacent to troughs 130 provides the user(not shown) with support and firmness characteristics that would beexpected from a non-sculptured foam mattress having foam that is lessfirm than the foam comprising sculptured foam core 94. Thus, by varyingdepth 160 and width 162 of troughs 130, the support and firmnesscharacteristics of portions of sculptured foam core 94 can be varied.

[0093] In preferred embodiments, troughs 130 are formed in top surface132 of sculptured foam core 94. It has been found, however, that bysculpturing troughs 130 onto the surface of sculptured foam core 94engaging the bed so that sculptured foam core 94 presents a generallyplanar top surface 132 provides for decreases of the firmness andsupport characteristics of mattress 52 carrying sculptured foam core 94,these decreases being less than the decreases experienced when thesculptured surface faces upwardly. Thus, by sculpturing sculptured foamcore 94 on the downward surface engaging the bed, the firmness andsupport characteristics of mattress 52 can be further adjusted. It iswithin the scope of the invention as presently perceived to sculpt thesculptured foam core to include troughs 130 only on top surface 132,only on the downwardly-facing surface of sculptured foam core 94engaging the bed, and on both above-mentioned surfaces.

[0094] Side foam sections 80 of frame 74 and foam divider rail 114 canalso be sculptured to allow for each of these members 80, 114 to move asshown in FIG. 7 along with head, seat, thigh, and foot sections 144,146, 148, 150 of articulating deck 138. Foam divider rail 114 istypically sculptured to have the same pattern of troughs 130 and cuts134 as described above with respect to sculptured foam core 94.

[0095] In preferred embodiments, frame 74 is formed from foam having asignificantly greater firmness than core 88 so that frame 74 providesadditional support along the sides and ends of mattress 52. Suchadditional support is particularly useful when a user enters and exitsthe bed. However, use of such additionally firm side foam sections 80requires that side foam sections 80 are sculptured to ensure that sidefoam sections 80 move with the head, seat, thigh, and foot sections 144,146, 148, 150 of deck 138.

[0096] As with sculptured foam core 94, side foam sections 80 of frame74 are provided with transverse cuts 134 having slits 140 andcylindrical openings 142 as shown in FIG. 7. Side foam sections 80 canalso be provided with troughs 130 to vary the firmness and supportcharacteristics of side foam sections 80 as described above with respectto sculptured foam core 94.

[0097] Core 88 can also include air bladder 96 as shown in FIGS. 1(a),2, and 8(a)-15. Air bladder 96 is preferably inflated and deflated usingair, however any acceptable fluid such as other gasses or liquids suchas water and water having additives to adjust the viscosity of theresultant liquid can be used to inflate air bladder 96 without exceedingthe scope of the invention as presently perceived. Thus, throughout thespecification and claims such fluid will be referred to as air, althoughit is understood that other fluids may be used.

[0098] Air bladder 96 can be a “one-zone” air bladder (not shown) havingone continuous air pocket extending through the air bladder so that theentire air bladder is uniformly inflated and deflated each time air isadded to or removed from the air bladder. In preferred embodiments,however, air bladder 96 is a multiple-zoned air bladder havingindependently inflatable zones. Preferred and illustrative air bladder96 is a “four-zone” air bladder 96 as shown in FIGS. 8(a) and 9 havingindependently inflatable zones including an upper back zone 192supporting the scapula, a lower back zone 194 supporting the lumbarregion, a seat zone 196 supporting the sacrum, and a foot zone 198supporting the thighs, legs, and feet of the user.

[0099] Air bladder 96 is constructed from an upper sheet 210 of an airimpermeable material that is adhesively connected to a lower sheet 212of an air impermeable material by a perimetral bead 214 of adhesiveapplied therebetween as shown in FIGS. 8(a), 8(b), and 9 to form anair-tight perimetral seal. Upper and lower sheets 210, 212 cooperatewith bead 214 to define an internal region 216 of air bladder 96 that isair impermeable. Bead 214 is slightly spaced apart from outer edges ofupper and lower sheets 210, 212 forming a two-layered perimetral flange217.

[0100] Transversely extending I-beams 218, 219 are received inside ofinternal region 216 as shown in FIGS. 9 and 11-15. Each I-beam 218, 219includes a top lip 220 sewn and adhesively attached to upper sheet 210and a lower lip 222 sewn and adhesively attached to lower sheet 212 asshown best in FIGS. 11 and 14. The adhesive forms an air impermeableseal between top lip 220 and upper sheet 210 and between lower lip 222and lower sheet 212. Each I-beam 218, 219 cooperates with upper sheet210, lower sheet 212, and each adjacent I-beam 218, 219 to define apocket 224 so that when air bladder 96 is inflated it defines alongitudinally extending series of transverse pockets 224 as shown bestin FIGS. 8(a), 8(b), 9, and 11-15. Each pocket 224 is a predeterminedsize when pocket 224 is inflated to its full capacity.

[0101] Each I-beam 218, 219 has a transverse first end 226 and atransverse second end 228 as shown in FIG. 8(a). First and second ends226, 228 of I-beams 218 are spaced apart from bead 214 to defineopenings 230 in fluid communication with adjacent pockets 224 defined byI-beams 218, thereby allowing the passage of air therebetween. However,first and second ends 226, 228 of I-beams 219 are adhesively attached tobead 214 to form air impermeable seals between adjacent pockets 224defined by I-beams 219. Thus, adjacent pockets 224 defined by I-beams219 are not in fluid communication through I-beams 219. I-beams 219 areplaced to define each of the separate and distinct upper back, lowerback, seat, and foot zones 192, 194, 196, 198 of air bladder 96 as shownin FIGS. 8(a), 8(b), and 9.

[0102] Each zone 192, 194, 196, 198 is provided with a tube 232 in fluidcommunication with pockets 224 of each respective zone 192, 194, 196,198, and tubes 232 are each in fluid communication with a pressurizedair supply 234 as shown diagrammatically in FIG. 8(a). Preferredpressurized air supply 234 includes a source of compressed air 236 suchas an air compressor, a pressurized air tank, or the like, a manifold238 connecting each tube 232 to source of compressed air 236, and valves240 individually controlling the flow of compressed air to and from eachtube 232 as shown in FIGS. 1(a), 2, and 8(a). In preferred embodiments,manifold 238 is positioned to lie in an opening 243 formed in foot endfoam section 78 of frame 74 as shown in FIGS. 1(a) and 2.

[0103] Valves 240 include a three-way normally open source/exhaust valve260 connecting manifold 238 to source of compressed air 236 whensource/exhaust valve 260 is open and connecting manifold 238 to anexhaust line 258 when source/exhaust valve 260 is energized as shown inFIGS. 8(a) and 8(b). An upper back valve 262 is a normally closed valvethat connects upper back zone 192 to manifold 238 when upper back valve262 is energized. A lower back valve 264 is a normally closed valve thatconnects lower back zone 194 to manifold 238 when lower back valve 264is energized. A seat valve 266 is a normally closed valve that connectsseat zone 196 to manifold 238 when seat valve 266 is energized. A footvalve 268 is a normally closed valve that connects foot zone 198 tomanifold 238 when foot valve 268 is energized.

[0104] To increase the support and firmness characteristics of mattress52 having four-zone air bladder 96 adjacent to upper back zone 192, theuser energizes upper back valve 262 to bring upper back zone 192 intofluid communication with manifold 238 as shown in FIG. 8(a).Source/exhaust valve 260 is normally open so that when upper back zone192 is in fluid communication with manifold 238, upper back zone 192 isalso in fluid communication with source of compressed air 236 so thatupper back zone 192 inflates. Likewise, to increase the firmness andsupport characteristics of matters 52 adjacent to lower back, seta, orfoot zones 194, 196, 198, the user simply energizes lower back valve,seat valve, or foot valve 264, 266, 268 respectively to bring therespective zone 194, 196, 198 of air bladder 96 into fluid communicationwith source of compressed air 236. To increase the firmness and supportcharacteristics of the entire mattress 52 simultaneously, the usersimply energizes all four of the upper back, lower back, seat, and footvalves 262, 264, 266, 268 simultaneously to bring all four zones 192,194, 196, 198 into fluid communication with source of compressed air 236at the same time.

[0105] To decrease the support and firmness characteristics of mattress52 having four-zone air bladder 96 adjacent to upper back zone 192 toprovide the user with a more plush feel, the user energizessource/exhaust valve 260 to bring manifold 238 into fluid communicationwith exhaust line 258 as shown in FIGS. 8(a) and 8(b), and thenenergizes upper back valve 262 to bring upper back zone 192 into fluidcommunication with manifold 238. Typically, exhaust line 258 ventsdirectly to the atmosphere, so that energizing both source/exhaust valve260 and upper back valve 262 brings upper back zone 192 into fluidcommunication with the atmosphere, causing upper back zone 192 todeflate and providing mattress 52 with a more plush feel for the user.

[0106] Likewise, to decrease the firmness and support characteristics ofmattress 52 adjacent to lower back, seat, or foot zones 194, 196, 198,the user simply energizes lower back valve, seat valve, or foot valve264, 266, 268 respectively to bring the respective zone 194, 196, 198 ofair bladder 96 into fluid communication with manifold 238, and thus therespective zone 194, 196, 198, and at the same time energizessource/exhaust valve 258 to bring manifold 238, and thus the respectivezone 194, 196, 198, into fluid communication with exhaust line 258 asshown in FIGS. 8(a) and 8(b). To decrease the firmness and supportcharacteristics of the entire mattress 52 simultaneously, the usersimply energizes all five of the upper back, lower back, seat, foot, andsource/exhaust valves 262, 264, 266, 268, 260 simultaneously to bringall four zones 192, 194, 196, 198 into fluid communication with exhaustline 258 at the same time so that all four zones 192, 194, 196, 198simultaneously vent to the atmosphere.

[0107] If desired, manifold 238 and valves 240 can be rearranged to“link” the performance of separate zones of four zone air bladder 96 asshown in FIG. 8(b). For example, tube 232 communicating with upper backzone 192 can also be brought into fluid communication with tube 232communicating with seat zone 196 by connector tube 263 communicatingwith both upper back zone 192 and seat zone 196. Connector tube 263 canbe brought into fluid communication with source of compressed air 236through an upper back and seat valve 267 and manifold 238 so that bothupper back and seat zones 192, 196 are inflated generally simultaneouslyand to the same extent to increase the firmness and supportcharacteristics of these zones 192, 196 of mattress 52. Connector tube263 can also be brought into fluid communication with exhaust line 258to simultaneously and to the same extent deflate both upper back andseat zones 192, 196, and decrease the firmness and supportcharacteristics of mattress 52 accordingly.

[0108] As can be seen, any two or more of zones 192, 194, 196, 198 canbe linked by a connector tube to cause separate portions of mattress 52to provide similar firmness and support characteristics. Likewise, asecond connector tube 265 can be formed to bring tubes 232 not connectedto the first common line into fluid communication. For example, if upperback and seat zones 192, 196 are in fluid communication throughconnector tube 263, tube 232 communicating with lower back zone 194 canbe brought into fluid communication with tube 232 communicating withfoot zone 198 by second connector tube 265 so that lower back zone 194is in fluid communication with foot zone 198. By bringing secondconnector tube 265 into fluid communication with source of compressedair 236, both lower back and foot zones 194, 198 will simultaneouslyinflate, increasing the firmness and support characteristics of mattress52 adjacent to lower back and foot zones 194, 198 at the same time andto the same extent. Likewise, by bringing the second connector tube 265into fluid communication with exhaust line 258, the firmness and supportcharacteristics of mattress 52 adjacent to lower back and foot zones194, 198 will decrease generally simultaneously and generally to thesame extent. Thus, independent zones of air bladder 96 can be linked sothat the support and firmness characteristics of mattress 52 adjacent tothe linked zones change at the same time to the same extent whenadjusted by the user.

[0109] In preferred embodiments of mattress 52 having four-zone orone-zone air bladder 96, the pressure of each zone 192, 194, 196, 198can be automatically controlled by placing air bladder 96 into“computer” mode. Once a user establishes a desired pressure for eachzone 192, 194, 196, 198 that results in the desired firmness and supportcharacteristics, the pressure in one or more of the zones 192, 194, 196,198 can change. For example, if the user moves so that a heavier orlighter portion of the user's body is supported by the affected zone,the pressure in the affected zone will change, changing the firmness andsupport characteristics of the affected zone.

[0110] Each zone 192, 194, 196, 198 of air bladder 96 is provided with atransducer 296 for providing an output signal in response to thepressure of each respective zone 192, 194, 196, 198 so that the pressurein each zone 192, 194, 196, 198 can be monitored, and bed and mattressstructure 50 can be configured to compensate for these changes inpressure. For example, if the pressure in upper back zone 192 decreasesfrom a set point established by the user, upper back valve 262 can beautomatically energized to bring upper back zone 192 into fluidcommunication with source of compressed air 236 until the pressure inupper back zone 192 increases back to the set point, thus increasing thefirmness and support characteristics of mattress 52 to the selectedlevel. Likewise, if the pressure in seat zone 196 increases above theset point established by the user, seat valve 266 and source/exhaustvalve 260 can be automatically energized to bring seta zone 196 intofluid communication with exhaust line 258, deflating seta zone 196 untilthe pressure is reduced back to the set point, thus returning thesupport and firmness characteristics of mattress 52 adjacent to seatzone 196 to the selected level. By monitoring and adjusting the pressurein each zone 192, 194, 196, 198 of air bladder 96, the user's selectedsupport and firmness characteristics can be maintained.

[0111] When mattress 52 is sized for a king- or queen-sized bed as shownin FIG. 2 and core 88 includes two side-by-side air bladders 96, onesource of compressed air 236 can be used to inflate and deflate both airbladders 96. Typically, each air bladder 96 is provided with manifold238 and valves 240, with each source/exhaust valve 260 being in fluidcommunication with a “T-connector” (not shown) bringing eachsource/exhaust valve 260 into fluid communication with source ofcompressed air 236.

[0112] As described above, both air bladders 96 can operate in a“computer” mode wherein the pressure of each respective zone 192, 194,196, 198 is maintained by automatically inflating and deflating eachzone to compensate for movement of the user that changes the loadcarried by each respective zone. The above-described valve configurationin accordance with the present invention prevents a “continuous run”condition. A continuous run condition is present in side-by-side airbladders 96, both of which are on computer mode, when one air bladder 96is exhausting so that one manifold 238 is in fluid communication withexhaust line 258 at the same time the other air bladder 96 is inflatingso that the other manifold 238 is in fluid communication with source ofcompressed air 236. Since both manifolds 238 are connected by theT-connector, the possibility exists that compressed air source 236 mightbe in fluid communication with exhaust line 258 so that neither airbladder 96 reaches the desired state, causing the system to runcontinuously as it attempts to inflate and deflate each air bladder.

[0113] However, each source/exhaust valve 260 is a three-way valve thatpositively blocks the flow between exhaust line 258 and manifold 238when source/exhaust valve 260 is open to bring manifold 238 into fluidcommunication with source of compressed air 236. In addition,source/exhaust valve 260 blocks the flow from source of compressed air236 when source/exhaust valve 260 is energized to bring manifold 238into fluid communication with exhaust line 258. Thus, use of a three-wayvalve for source/exhaust valve 260 eliminate the possibility ofinadvertently achieving a continuous run condition when operating twoside-by-side air bladders.

[0114] The operation of a one-zone air bladder 96 as shown in FIG. 10 issimpler than the operation of four-zone air bladder 96. An inlet valve292 is normally open to block the fluid communication between source ofcompressed air 236 and manifold 238. Likewise, an exhaust valve 294 isnormally closed to block the fluid communication between exhaust line258 and manifold 238. Manifold 238 is in fluid communication with airbladder 96 and a transducer 296 for converting a measured pressure to anoutput signal for use by a controller 370 is in fluid communication withair bladder 96 through manifold 238. To increase the firmness andsupport characteristics of mattress 52 having one-zone bladder 96, usersimply energizes inlet valve 292 to restore fluid communication betweensource of compressed air 236 and air bladder 96 through manifold 238 toinflate air bladder 96. To decrease the firmness and supportcharacteristics of mattress 52, user energizes exhaust valve 294 torestore fluid communication between exhaust line 258 and air bladder 96through manifold 238 to deflate air bladder 96.

[0115] I-beams 218, 219 are generally of similar height so that pockets224 are generally uniform in size and shape as shown in FIG. 9. Theheight of I-beams 218, 219 can be varied as shown in FIGS. 11-14 forI-beams 218′ which are taller than I-beams 218, 219 to produce pockets224′ defined by I-beam 218′ that inflate to a size larger than pockets224 that are not adjacent to I-beam 218′. Pockets 224′ produce a portionon mattress 52 adjacent to pockets 224′ at which the user perceivesadditional support and firmness. By placing I-beam 218′ as shown inFIGS. 11-15, air bladder 96 will provide additional support and firmnessfor the lumbar portion of the user's adjacent to the lower back zone194.

[0116] Typically, I-beams 218, 219 are generally the same height so thatpockets 224 are generally uniform in size and shape as shown in FIG. 9.Air bladder 96 can be made, however, having selected I-beams 218′ whichare taller than I-beams 218, 219 as shown in FIGS. 11-15 to producepockets 224′ defined by taller I-beams 218′ that inflate to a sizelarger than pockets 224 defined only by I-beams 218, 219 so that upperand lower sheets 210, 212 adjacent to pockets 224′ project beyond upperand lower sheets 210, 212 adjacent to pockets 224 defined only byI-beams 218, 219 when pockets 224, 224′ are fully inflated, as shownbest in FIG. 15. By including isolated pockets 224′ that project pastthe other surfaces of air bladder 96, mattress 52 provides additionalfirmness and support characteristics at longitudinal zones adjacent toprojecting pockets 224′.

[0117] For example, a single I-beam 218′ can be positioned to liebetween two I-beams 218, 219 as shown diagrammatically in FIGS. 11 and12 for air bladder 96 resting on a generally planar surface. When airbladder 96 is fully inflated, upper sheet 210 adjacent to two adjacentpockets 224, which are both defined in part by I-beam 218′, projectsabove upper sheet 210 adjacent to pockets 224 as shown in FIG. 11.Likewise, two adjacent I-beams 218′ can be positioned to lie betweenI-bemas 218, 219 as shown diagrammatically in FIGS. 13 and 14 for airbladder 96 resting on a generally planar surface. When air bladder 96 isfully inflated, upper sheet 210 adjacent to three adjacent pockets 224′,each of which are defined at least in part by I-bemas 218′, projectsabove upper sheet 210 adjacent to pockets 224 as shown in FIG. 14.Although only one and two adjacent I-beams 218′ that are taller thanI-beams 218, 219 are shown in FIGS. 11-15, the height of any number ofadjacent I-beams 218′ may be varied to cause a desired portion of upperand lower sheets 210, 212 of air bladder 96 to project beyond theremaining portions of upper and lower sheets 210, 212.

[0118] Taller I-beams 218′ can be used to provide firmness and supportcharacteristics that vary longitudinally along mattress 52 including airbladder 96 as shown in FIG. 15, even if air bladder 96 is a one-zone airbladder. In addition, use of taller I-beams 218′ can cause each zone ofa multiple zone air bladder 96 to provide mattress 52 with multiplefirmness and support characteristics adjacent to the zone.

[0119] For example, I-beams 218′ can be used to form pockets 224′ infoot zone 198 adjacent to seat zone 196 as shown in FIG. 15. Mattress 52including air bladder 96 with such pockets 224′ will provide the userwith additional firmness and support adjacent to his or her thighs. Thusfoot zone 198, which includes pockets 224, 224′ that are all in fluidcommunication so that the air pressure in each pocket 224, 224′ of footzone 198 is generally equivalent, will simultaneously provide theportion of mattress 52 adjacent to foot zone 198 with multiple firmnessand support characteristics.

[0120] For another example, I-beams 218′ can be used to form pockets224′ in foot zone 198 adjacent to the ankles of the user as shown inFIG. 15. Mattress 52 including air bladder 96 with such pockets 224′will provide the user with additional firmness and support adjacent tohis or her ankles. In addition, by providing this additional supportadjacent to the ankles of the user, mattress 52 will operate to relieveinterface pressure against the heels of the user to help alleviatepressure ulcers that can develop on the heels of the user. Air bladder96 can thus be used to adjust the support and firmness characteristicsof mattress 52 both by having adjustable air pressure in one or multiplelongitudinal zones, for example zones 192, 194, 196, 198, and by suingI-beams 218′ that are taller than other I-bemas 218, 219 so thatportions of upper and lower sheets 210, 212 of air bladder 96 projectbeyond portions of upper and lower sheets 210, 212 adjacent only toI-beams 218, 219.

[0121] Flange 217 of air bladder 96, which is positioned to lie outsideof perimetral bead 214 as shown in FIGS. 8(a), 8(b), and 9, is formedfrom outer portions of both the upper and lower sheets 210, 212. Flange217 is formed to include a plurality of spaced-apart openings 244 thatextend therethrough. Openings 244 are used during the manufacturingprocess to stabilize air bladder 96 as manufacturing operations areperformed thereon.

[0122] Openings 244 can also be used, however, to stabilize air bladder96 in mattress 52. For example, when mattress 52 is provided for aqueen-sized bed (not shown) so that core 88 includes elements inside-by-side abutting engagement, if core 88 includes side-by-side airbladders 96, then openings 244 of the first air bladder 96 can be tiedto openings 244 of the second air bladder 96 to prevent relativetransverse movement of the first air bladder 96 relative to the secondair bladder 96. Even if core 88 includes side-by-side elements only oneof which is an air bladder 96, openings 244 can still be used tostabilize air bladder 96 if desired.

[0123] In preferred embodiments of bed and mattress structure 50, topcover 60 of mattress 52 can be formed to include an enclosed “warm airrelease” channel 250 receiving air from source of compressed air 236 asshown in FIG. 16. Enclosed channel 250 is preferably made from a lightweight and air impermeable material so that air is directed along thelength of channel 250. The material is formed to include small openings(not shown) that allow a small amount of air to escape from channel 250.The openings direct the air across the surface of mattress 52 as shownby arrows 252 in FIG. 12.

[0124] An air heater 254 is interposed between source of compressed air236 and channel 250 as shown in FIG. 16 so that heated air can beprovided to channel 250. Air heater 254 can be selectively operated sothat when air heater 254 is operating, air 252 is the warm air releasewarming the user and particularly warming the extremities of the user.When air heater 254 is not operating, air 252 is a room temperature airrelease cooling the user during operation of channel 250. Of course, inpreferred embodiments, a valve is positioned between source ofcompressed air 236 and channel 250 so that channel 250 can be operatedor not operated at the discretion of the user.

[0125] Channel 250 can be positioned about the perimeter of top cover 60as shown in FIG. 16. As mentioned above, the preferred material ofconstruction of much of mattress 52 is foam rubber which is a thermalinsulator. As such, it is important that channel 250 be as close aspossible to sleeping surface 122 and the user. As a result, if mattress52 includes pillow top 90, then channel 250 can be formed around anouter edge of pillow top 90 rather than top cover 60 so that channel 250is adjacent to sleeping surface 122.

[0126] Also in preferred embodiments, a hand held controller 256 isprovided for use by the user as shown in FIG. 16 for controlling theoperation of bed and mattress structure 50. Hand held controller 256 canoperate both source of compressed air 236 and air heater 254 as well asother mattress functions as described in detail below with reference toFIGS. 21 and 22.

[0127] Bed and mattress structure 50 can additionally be provided witharm rests 270 as shown in FIGS. 17-20. Arm rest 270 includes a curvedtop surface 272, a curved bottom surface 274, and generally planar sides276. Top and bottom surfaces 272, 274 can each be formed to includeopenings 278 sized to receive drinking glasses, drinking cups, beveragecans, or the like (shown in phantom in FIG. 18). The preferred arm rest270 includes a foam rubber pad 280 and a fabric covering 282conformingly shaped to fit around pad 280 as shown best in FIG. 18. Topand bottom surfaces 272, 274 are spaced apart by a first distance 284near a first end 286 of arm rest 270 and taper together so that top andbottom surfaces 272, 274 are spaced apart by a second distance 288 neara second end 290 of arm rest 270.

[0128] Arm rest 270 is positioned between the elbow of the user (notshown) and sleeping surface 122. The distance between the elbow andsleeping surface 122 varies somewhat between users resting on sleepingsurface 122. By moving arm rest 270 longitudinally relative to the elbowof the user, most users will find a position on arm rest 270 having adistance between top and bottom surfaces 272, 274 at which the user cancomfortably rest his or her elbow. If the user finds that it is mostcomfortable to rest his or her elbow nearer to first end 286 than tosecond end 290, the user will most likely prefer to use arm rest 270with top side 272 facing upwardly as shown in FIG. 19 so thatupwardly-facing opening 278 is on the portion of arm rest 270 extendinglongitudinally away from seat section 146. Conversely, if the user findsthat it is most comfortable to rest his or her elbow nearer to secondend 290 than to first end 286, the user will most likely prefer to usearm rest 270 with bottom side 274 facing upwardly as shown in FIG. 20 sothat once again upwardly-facing opening 278 is on the portion of armrest 270 extending longitudinally away from seat section 146. It can beseen in each instance that the shapes of top and bottom surfaces 272,274 generally conform to the shape of sleeping surface 122 of mattress52 when deck 138 is articulated away from the generally planar sleepingposition.

[0129] As mentioned above, hand held controller 256 is provided as shownin FIGS. 16, 21, and 22 for controlling the operation of bed andmattress stricture 50. Hand held controller 256 includes a first end310, a second end 312, a power and communication cord 314 extending awayfrom second end 312 and toward bed and mattress stricture 50, an upperface 316, and a key pad 318 carried on upper face 316 for receivinginputs from the user, bed and mattress structure 50 adjusting itsvarious features in response to the inputs from keypad 318 as describedbelow. When the user is holding hand held controller 256 to operate bedand mattress structure 50, hand held controller 256 will typically beheld in a generally upright orientation as shown in FIG. 21 having firstend 310 positioned to lie generally above second end 312.

[0130] Illustrative key pad 318 includes a light emitting diode (LED)primary display 320, memory buttons 322, bed position buttons 324,mattress control buttons 326, massage control buttons 328, and a bedselect button 330 as shown in FIG. 22. In addition, key pad 318 includesan LED computer on/off display 332, an LED zone display 334, and an LEDbed select display 336. As described below, illustrative key pad 318 isconfigured for use with a king- or queen-sized bed having anarticulating deck 138 and having at least one four-zone air bladder 96.Other beds having other features would include hand held controller 256having a key pad 318 including at least some of these buttons.

[0131] Key pad 318 is arranged so that primary display 320 is positionedadjacent to first end 310 of key pad 318 as shown in FIG. 22. Theremaining buttons and displays are positioned to lie in longitudinallyspaced-apart relation between primary display 320 and second end 312.Memory buttons 322 are positioned adjacent to primary display 320, bedposition buttons 324 are positioned adjacent memory buttons 322,mattress control buttons 326 are positioned adjacent bed positionbuttons 324, massage control buttons 328 are positioned adjacentmattress control buttons 326, and bed select button 330 is positionedadjacent massage control buttons 328 and adjacent second end 312 of keypad 318.

[0132] Memory buttons 322 provide the user with the ability to establishone or more preferred “memory positions” of articulating deck 138. Inaddition, the memory positions include a corresponding air pressure inzones 192, 194, 196, 198 of air bladder 96 selected by the user toprovide selected firmness and support characteristics to correspond toeach preferred position of articulating deck 138, as shown in FIG. 22 inwhich illustrative key pad 318 allows the user to establish two memorypositions. Once the user establishes the memory positions, the usersimply presses the memory button corresponding to the desired positionand articulating deck 138 will automatically move to its prescribedposition while each zone 192, 194, 196, 198 of air bladder 96 isautomatically inflated or deflated to its prescribed pressure so thatmattress 52 provides the preselected firmness and supportcharacteristics selected by the user to correspond to the selectedposition of articulating deck 138.

[0133] Bed position buttons 324 allow the user to manipulate thearticulating sections of articulating deck 138. In addition, certain ofthe individual LEDs of primary display 320 will be energized to indicatethe relative position of articulating deck 138. In addition, primarydisplay 320 indicates the relative air pressure in zones 192, 194, 196,198 of air bladder 96. Primary display 320 will provide an indicationfor the last button pressed. If more than one function is running onetime or if memory buttons 322 are pressed, primary display 320 willindicate the relative position of head section 144 of deck 138. Also,bed position buttons 324 include a preset “lounge” button 338 and apreset “bed flat” button 340 which are additional memory keys that areset during assembly of mattress 52 in accordance with inputs from thecustomer profile sheet.

[0134] Mattress control buttons 326 shown in FIG. 22 include a “zones”button 342 for selecting a zone 192, 194, 196, 198 of air bladder 96 inresponse to user pressing zones button 342, zone display 334 includingLED indicators, one of which will be energized to indicate the selectedzone 192, 194, 196, 198, a “firm” button 344 for increasing the airpressure in the selected zone in response to user pressing firm button344 to increase the firmness of mattress 52 adjacent to the selectedzone, and a “soft” button 346 for decreasing the air pressure in theselected zone in response to user pressing soft button 346 to decreasethe firmness of mattress 52 adjacent to the selected zone. As describedabove, when the user presses zones button 342 to select a selected zone,primary display 320 will indicate the relative air pressure in theselected zone.

[0135] In addition, mattress control buttons 326 include a mattresscomputer on/off button 348. Once a user has selected a desired airpressure for each zone 192, 194, 196, 198, the user may move relative toair bladder 96. As the user moves, heavier or lighter body parts of theuser may be supported by each respective zone 192, 194, 196, 198 thanwere support by the zone when the desired air pressure was originallyselected. If the amount of air in zones 192, 194, 196, 198 were fixed,this movement of user could change the forces exerted on each zone 192,194, 196, 198, thus changing the air pressure in each zone and thesupport and firmness characteristics of mattress 52 adjacent to eachzone 192, 194, 196, 198.

[0136] Mattress 52 preferably includes transducers 296, described abovewith reference to FIGS. 8(a), 8(b), and 10, for measuring the airpressure in each zone 192, 194, 196, 198. If, after selecting thedesired firmness and support characteristics for each zone 192, 194,196, 198 the user presses computer on/off button 348 to turn on the“computer mode,” an internal computer will monitor output signalsprovided from each transducer 296 in response to the air pressure ineach zone 192, 194, 196, 198 and will automatically operate valves 240when necessary and in the manner described above with reference to FIGS.8(a) and 8(b) to maintain the pressure in each respective zone 192, 194,196, 198 at a set point that corresponds to the firmness and supportcharacteristics chosen by the user. If computer mode is turned on, theLED of computer on/off display 332 will be energized to indicate suchstatus.

[0137] Mattress 52 can also be provided with a massage feature. Thepresently preferred massage feature is provided by first and secondmotors (not shown), the first motor being attached to articulating deck138 adjacent to head section 144 and the second motor being attached toarticulating deck 138 adjacent to foot section 150. Each motor rotates agenerally horizontally extending shaft. An off-center weight is fixed toeach shaft so that as each shaft rotates, each shaft, each motor, anddeck 138 adjacent to each motor vibrates. To increase the level ofvibration felt by the user, the rotation speed of the shafts isincreased and to decrease the level of vibration felt by the user, therotation speed of the shaft is decreased.

[0138] As mentioned above, mattress control buttons 326 include massagecontrol buttons 328, including head end massage increase button 350,head end massage decrease button 352, foot end massage increase button354, foot end massage decrease button 356, and wave buttons 358. Whenthe user presses head end massage increase button 350, the motorattached to articulating deck 138 adjacent to head section 144 increasesthe rotational speed of its shaft until a maximum rotational speed isreached at which point the rotational speed of the shaft cannot befurther increased.

[0139] When the user presses head end massage decrease button 352, themotor attached to articulating deck 138 adjacent to head section 144decreases the rotational speed of its shaft until a minimum rotationalspeed is reached. The motor will halt the rotation of the shaft if headend massage decrease button 352 is pressed when the shaft is rotating atthe minimum rotational speed. Likewise, pressing foot end massageincrease button 354 and foot end massage decrease button 356 causes themotor attached to articulating deck 138 adjacent to foot section 150 toincrease and decrease the rotational speed of its shaft. Pressing wavebuttons 358 causes the motors to operate together to provide acoordinate massage effect.

[0140] Finally, if mattress 52 is for a queen- or king-sized bed havingside-by-side air bladders 96, hand held controller 256 will control bothhalves of bed and mattress structure 50. Pressing bed select button 330,shown in FIG. 22, will toggle between the two halves of the bed andmattress structure 50 so that when the “left” LED of bed select display336 is energized control inputs from the user to key pad 318 willoperate to manipulate the left side of bed and mattress structure 50,and when the “right” LED of bed select display 336 is energized, controlinputs from the user to key pad 318 will operate to manipulate the rightside of bed and mattress structure 50.

[0141] Typically when the user operates bed and mattress structure 50including articulating deck 138 and four-zone air bladder 96 usingillustrative key pad 318 shown in FIG. 22, the user will press one ofmemory buttons 322. However, on occasion, the user may choose to adjustthe position of articulating deck 138 using bed position buttons 324 andmay probably less frequently, wish to adjust the support and firmnesscharacteristics of mattress 52 by pressing mattress control buttons 326.Occasionally, the typical user will utilize the massage feature bypressing massage control buttons 328.

[0142] Thus, illustrative key pad 318 is arranged so that buttons areordered from first end 310 to second end 312, or from top to bottom, inorder of the frequency of use of the buttons so that the most frequentlyused buttons are positioned to lie nearest the top or first end 310 ofkey pad 318 and the least frequently used buttons are nearest the bottomor second end 312 of key pad 318. In addition, it can also be seen thatillustrative key pad 318 is arranged so that buttons are ordered fromfirst end 310 to second end 312, or from top to bottom of key pad 318,generally in the order that the user will use the buttons so that thefirst buttons generally used in a typical operation sequence are nearestthe top of key pad 318 and the last buttons used in a typical operationsequence are nearest the bottom of key pad 318.

[0143] Hand held controller 256 provides the man-machine interface forthe user. By depressing buttons 322, 324, 326, 328, 330 (graphicallydisplayed) the user can select various operations. These operations arebed position, mattress computer, memory, massage, mattress zones, andfirm or soft controls. These commands are sent by way of an RS232 wireconnection 372 to the compressor board 374 as shown in FIG. 23. Thecompressor board 374 acts as an interconnection interface to themattress control board 376, massage and bed position motors 378. Signalsgenerated at hand held controller 256 pass through compressor board 374to mattress control board 376. Mattress controller operates valves 240to control the flow of compressed air or exhaust from zone to zone.Mattress controller also receives signals from transducers 296 thatmonitor the air pressure at each zone and provides signals back to handheld controller 256 for display.

[0144] Hand held controller 256 is a microprocessor based control systemcapable of remotely controlling up to eight bladders or individual airzones of air bladders 96 via a serial link with pressure control system.The system will also receive and display relative pressure informationby way of the serial link. The link itself is to be either a wire or awireless link.

[0145] The system is based on a Microchip 16 C series surface mount onetime programmable device. There are two microcontrollers used. Onelocated in hand held controller 256 and the other is in mattress controlboard. They communicate VIA an RS232 serial link.

[0146] The primary benefit of the Microchip device is the implementationof control algorithms due to the controller's reduced instruction set.Additional benefits include:

[0147] Simplified memory requirement predictions, and timingcalculations due to the single line, predominantly single cycleinstructions.

[0148] Low Cost.

[0149] No additional program memory required.

[0150] Software is directly portable to other devices in the largefamily allowing for easier upgrades.

[0151] Specialized sleep capability, and external interrupts allow apower consumption savings.

[0152] Built in, independent watch dog timer prevents system crash dueto an unresponsive controller.

[0153] Separate program and data memory prevents unintentional programcorruption due to accidental program memory access.

[0154] A salient feature for this system is the implementation of adirect feed back display on key pad 318 at the man-machine interface.Primary display 320 presents the user with direct real time feed back ofcontrol operations. Mattress control board 376 receives signals fromtransducers 296 in response to the air pressure in each zone and usesthat information to display pressure setting and the controlled zones ofair bladder 96 on primary display 320 of hand held controller 256.

[0155] Mattress 52 is ideally suited for providing a user with sleepingsurface 122 that is customized to provide firmness and supportcharacteristics established by and for the user. As described above,mattress 52 can include air bladder 96 having either one zone ormultiple zones, and within each zone air bladder 96 can be provided withI-beams of varying height to provide multiple firmness and supportcharacteristics within each zone. Mattress 52 can also includesculptured foam core 94 or zone foam blocks 92 as described above. Inaddition, however, mattress 52 may be provided with combinations of theabove as shown in FIGS. 1(b) and 1(c).

[0156] Mattress 52 can be provided with a combination of zone foamblocks 92 and air bladders 96 as shown in FIG. 1(b) which illustrativelyshows air bladders 96 for supporting the scapula and sacrum of the userand zone foam blocks 92 for supporting the lumbar region and the thighsand legs of the user. Air bladders 96 can operate individually andseparately, or air bladders 96 can be brought into fluid communicationwith one another in a manner similar to that described above withrespect to FIG. 8(b) so that they inflate and deflate generally at thesame time and to generally the same extent.

[0157] Likewise, mattress 52 can illustratively include zone foam blocks92 positioned to support the upper back, the seat, and the lower legs ofthe user and air bladders 96 to support the lumbar region and thighs ofthe user as shown in FIG. 1(c). As mentioned above, air bladders 96 canoperate individually and separately, or air bladders 96 can be broughtinto fluid communication with one another in a manner similar to thatdescribed above with respect to FIG. 8(b) so that they inflate anddeflate generally at the same time and to generally the same extent. Ascan be seen, any combination or positioning of zone foam blocks 92 andair bladders 96 can be provided in mattress 52 to meet the desiredfirmness and support characteristics of the user. Although preferredsculptured foam core 94 generally extends the full length of centralopening 82, shorter sculptured foam cores (not shown) can be providedfor use in combination with air bladders 96 and zone foam blocks 92 ifdesired to provide the user with his or her preferred firmness andsupport characteristics without exceeding the scope of the invention aspresently perceived.

[0158] Mattress 52 along with a “test mattress” (not shown) containing amultiple zone air bladder 96 can be used to determine the firmness,support, and interface pressure preferences of the user and to use thesame to customize mattress 52 for each user. The preferred method forcustomizing mattress 52 is initiated when a potential user completes aquestionnaire to aid in the analysis of that user's “sleep profile.” Thesleep profile assesses such factors as the user's general health andsleep habits. A firmness recommendation is computed either in terms of apressure for various zones of the test mattress or in terms of a foamtype and density for each zone. In addition, a surface recommendation isestablished based on the user's responses to a surface recommendationquestionnaire.

[0159] Once the surface and hardness recommendations are established,the user lies on the test mattress and air bladder 96 is pressurized tomatch the firmness recommendation. Zones of air bladder 96 are thenadjusted to match the preferences of the user and the resultingpreferred firmness readings are recorded.

[0160] An algorithm has been developed that correlates the air bladderpressure readings once the preferred firmness and supportcharacteristics have been established by the user into a customized bedconfiguration. For example, the preferred firmness readings can betranslated to establish the foam density that, if incorporated into amattress will provide the firmness and support characteristics similarto those provided by the test sleeping surface having the preferredfirmness readings.

[0161] This correlation can be developed by comparing the deformation ofair bladder 96 having a selected air pressure when a known force isapplied thereto by a probe of a known size, and then determining a foamILD that provides the same deflection when the same force is applied tothe foam by the same probe. A pressure deformation response curve can bedeveloped that shows the foam ILD that provides generally the samedeflection as air bladder 96 for various air pressures within bladder96.

[0162] Once the air pressure readings have been found that provide theuser with his or her preferred firmness, support, and interface pressurecharacteristics, mattress 52 can be prepared using the pressuredeformation response curve so that mattress 52 has mattress structurecomponents or cores 88 including sculptured foam core 94, zone foamblocks 92, air bladder 96, or a combination thereof that provide theuser with the preferred characteristics. In addition, if desired, acomputer can be used to map the pressure readings of the test mattressafter finding the user's preferred firmness and support characteristicsand a program can utilize the pressure map and the pressure deformationresponse curve to determine the arrangement of mattress structurecomponents that will provide mattress 52 that meets the user'spreferences.

[0163] Once the customized bed configuration is established, mattress 52can be assembled from a kit at the point of sale containing theplurality of cores 88 for the user to test and verify that assembledmattress 52 meets his or her preferences. If mattress 52 is notsatisfactory, cores 88 can be replaced at the point of sale. Once theuser is satisfied with the arrangement of cores 88, he or she canimmediately take delivery of the completed customized mattress ifdesired. In the alternative, once the customized bed configuration isestablished, the data describing this configuration can be transmittedto a factory at which the mattress 52 can be assembled for delivery tothe user.

[0164] In addition, if the user determines after assembly and deliverythat the user prefers alternate firmness or support characteristics,cores 88 can again be readjusted or upgraded until the mattress 52provides the desired firmness and support characteristics. If desired, akit of cores 88 can be provided to the user so that the user can adjustthe firmness and support characteristics.

[0165] The method for selecting mattress structure components or cores88 to provide a customized foam mattress 52 to accommodate themusculoskeletal condition of the user includes providing a plurality ofmattress structure components arranged for selective assembly of thecomponents. The components comprise a plurality of foam cores 88 forfilling longitudinally extending central opening 82 in mattress 52 abovewhich the user rests. Foam cores 88 should have a variety of shapes andsupport and firmness characteristics from which to select a desiredassembly.

[0166] The method also includes providing a test mattress having asimilar longitudinally extending central opening filled with a pluralityof longitudinally spaced apart air bladders extending transverselyacross the central opening and an air supply for selectively fillingeach air bladder to various pressures. A user is placed above thecentral opening of the test mattress and supported on the plurality ofair bladders. The air pressure in each bladder is adjusted to a selectedpressure to provide the support and firmness desired by the user. Anequivalent foam core having the desired support and firmnesscharacteristics corresponding to the selected air pressures is thenselected and placed in the central opening to provide the customizedmattress.

[0167] In preferred embodiments, the mattress 52 in accordance with thepresent invention can be sized for a twin bed or a double bed as shownin FIGS. 1(a)-1(c), or a queen-sized or a king-sized bed as shown inFIG. 2. When mattress 52 is sized for the queen and king-sized beds,both sides of mattress 52 can be individually customized if desired toprovide the firmness and support characteristics desired by individualsleep partners. Both cores 88 and toppers 86 can be selected for eachside of mattress 52 to provide the desired firmness and support for eachside of the bed. This flexibility results from the separate cores 88that are provided for each side of mattress 52.

[0168] In addition to this flexibility, use of distinct cores 88 foreach half of mattress 52 operates to reduce the transmission of movementfrom one side of mattress 52 to the other. Thus, when one sleepingpartners moves, the amount of movement experienced by the other sleepingpartner as a result is minimized.

[0169] As mentioned above, mattress 52 can be provided with an airbladder having independent zones that are selectively adjustable by theuser to provide varied firmness and support characteristics. If the samemattress 52 is used on a bed having articulating deck 138, mattress 52can be provided with hand held controller 256 for use by the user tocontrol the adjustment of both the position of deck 138 and the supportcharacteristics of each zone of air bladder 96. In addition, hand heldcontroller 256 can include a “memory set” feature which allows the userto establish preferred combination settings for deck 138 and mattress52.

[0170] In addition, the mattress can be provided with combinations ofair bladders 96, zone foam elements 92, and sculptured foam core 94 toproduce a “combination mattress.” Illustratively, mattress 52 can beprovided having air bladder 96 supporting the scapula of the user, zonefoam blocks 92 supporting the lumbar of the user, air bladder 96 in theseat portion supporting the sacrum of the user, and zone foam blocks 92supporting the thighs and legs. If desired, air bladders 96 can be influid communication so that they inflate and deflate at the same timesand to the same pressures or air bladders 96 can be independent of oneanother and independently controlled by the user so that the user canestablish different characteristics of support and firmness for each ofthe scapula and the sacrum.

[0171] Although the invention has been described in detail withreference to preferred embodiments, additional variations andmodifications exist within the scope and spirit of the invention asdescribed and defined in the following claims.

1. A control system for a bed and a mattress structure comprising aframe and a mattress comprising a plurality of longitudinally spacedapart, transversely extending air bladders and an air supply for fillingeach bladder to desired air pressures to support the user, the controlsystem comprising: an air controller cooperating with the air supply forfilling the air bladders to desired air pressures; a hand-heldcontroller in communication with the air controller, the hand-heldcontroller being configured for receiving air memory set inputs from theuser permitting the user to establish at least one preferredair-firmness setting in the air bladders and receiving at least one airmemory input from the user recalling the preferred air-firmnesssettings; and the air controller filling the air bladders to the atleast one preferred air-firmness setting in response to the air memoryinput.
 2. The control system of claim 1, wherein the air controllerincludes microprocessor and software in communication with the hand-heldcontroller for storing at least one air memory set input received fromthe hand-held controller and controlling the air supply controller toestablish desired bladder pressures in response to receiving the atleast one memory input from the hand-held controller.
 3. The controlsystem of claim 1, in which the hand-held controller includes a key padhaving a first end and a second end, the first end being positionedgenerally above the second end when held by the user, the key padincluding buttons arranged having the most frequently selected buttonspositioned near the first end, the least frequently selected buttonspositioned near the second end, and the remaining buttons positionedtherebetween in the order of frequency of use with the most frequentlyused buttons positioned nearest the first end.
 4. The control system ofclaim 1, in which the hand-held controller includes a key pad having afirst end and a second end, the first end being positioned generallyabove the second end when held by the user, the key pad includingbuttons arranged in the order that the user generally will use thebuttons in a typical operation sequence, the first buttons generallyused in the typical operation sequence being positioned nearest thefirst end and the last buttons generally used in the typical operationsequence being positioned nearest the second end.
 5. The control systemof claim 1, wherein the frame includes longitudinally spaced head, seat,thigh, and foot sections, the head, thigh, and foot sections beingmovable relative to each other and relative to the seat section andfurther comprising a drive controller for tilting the frame sections tovarious desired positions.
 6. The control system of claim 5, wherein thehand-held controller is further configured for receiving drive memoryset inputs from the user permitting the user to establish preferredpositions of the frame sections and for receiving at least one drivememory input from the user recalling the preferred position settings,the drive controller tilting the frame sections to the preferredposition setting in response to the drive memory input.
 7. The controlsystem of claim 6, wherein the drive controller includes microprocessorand software in communication with the hand-held controller for storingat least one drive memory set input received from the hand-heldcontroller and controlling the drive controller to establish desiredframe section positions in response to receiving the at least one drivememory input from the hand-held controller.
 8. A control system for abed and a mattress structure comprising a frame and a mattresscomprising a plurality of longitudinally spaced apart, transverselyextending air bladders and an air supply for filling each bladder todesired air pressures to support the user, the control systemcomprising: an air controller cooperating with the air supply forfilling the air bladders to desired air pressures; a hand-heldcontroller in communication with the air controller, the hand-heldcontroller including a key pad having a first end and a second end, thefirst end being positioned generally above the second end when held bythe user, the key pad including air adjustment buttons, a memory setbutton to establish at least one preferred air-firmness setting in theair bladders, and at least one memory button to recall the preferredair-firmness setting; and the air controller filling the air bladders tothe at least one preferred air-firmness setting in response to the useractivating the memory button.
 9. The control system of claim 8, whereinthe at least one memory set button is positioned to lie adjacent thefirst end of the key pad.
 10. The control system of claim 9, wherein theat least one memory button is positioned to lie adjacent the memory setbutton.
 11. The control system of claim 9, wherein the air adjustmentbuttons are positioned to lie between the at least one memory button andthe second end of the key pad.
 12. The control system of claim 8,wherein the air controller includes microprocessor and software incommunication with the hand-held controller for storing at least onememory set input received from the hand-held controller upon activationof the at least one memory set button and controlling the air supplycontroller to establish desired bladder pressures in response activationof at least one memory button.
 13. The control system of claim 8,wherein the frame includes longitudinally spaced head, seat, thigh, andfoot sections, the head, thigh, and foot sections being movable relativeto each other and relative to the seat section and further comprising adrive controller for tilting the frame sections to various desiredpositions.
 14. The control system of claim 13, wherein the drivecontroller includes microprocessor and software in communication withthe hand-held controller for storing at least one memory set inputreceived from the hand-held controller upon activation of the at leastone memory set key and controlling the drive controller to establishdesired frame section positions in response to activation of the atleast one memory key.
 15. The control system of claim 14, wherein theair controller includes microprocessor and software in communicationwith the hand-held controller for storing at least one memory set inputreceived from the hand-held controller upon activation of the at leastone memory set button and controlling the air supply controller toestablish desired bladder pressures in response activation of at leastone memory button.
 16. A hand held controller operable by a user for abed and mattress structure comprising an articulating frame includinglongitudinally spaced head, seat, thigh, and foot sections, the head,thigh, and foot sections being movable relative to each other andrelative to the seat section, the deck supporting the head and shoulder,seat, thigh, and feet of a user, a mattress interposed between the deckand the user, the mattress comprising a plurality of longitudinallyspaced apart, transversely extending air bladders correspondingrespectively to the frame sections, power driver for tilting the framesections to desired tilted positions, an air supply for filling eachbladder to desired air pressures to support the user, and a drivecontroller for controlling the power drive for tilting the framesections to various desired positions and an air supply controller forcontrolling the air supply for filling the air bladders to desired airpressures, the hand held controller comprising a substrate having agenerally upper first end, a generally lower second end, and a surfacetherebetween generally facing the user when the user operates the handheld controller, a cord extending from the second end of the substratefor carrying signals to the controller, a programmable device carried bythe substrate for storing and retrieving inputs from the user, and a keypad carried by the top surface of the substrate, the key pad cooperatingwith the programmable device to provide signals to the controllerthrough the cord in response to inputs from the user, the key padincluding memory set buttons providing the signals to the cord when thebuttons are activated by the user, the controller manipulating the powerdrive and the air supply in response to the signals, the buttons beingarranged so that buttons are ordered from the first end to the secondend in order of the frequency of use of the buttons so that the mostfrequently used buttons are positioned to lie nearest the first end andthe least frequently used buttons are nearest the second end of key pad,and a display mounted on the substrate and selectively indicating therelative position of the sections of the articulating frame and therelative pressure of the air bladders.
 17. The controller of claim 16,in which the display is positioned adjacent to the first end of thesubstrate.
 18. The controller of claim 16, in which the substrateincludes spaced-apart longitudinal first and second sides connecting thefirst and second ends and the display includes a plurality ofspaced-apart light emitting diodes extending transversely between thefirst and second sides.
 19. The controller of claim 18, in which theplurality of light emitting diodes cooperate to indicate the relativepositions of the sections of the articulating frames and the relativepressures of the air bladders by energizing individual light emittingdiodes which cooperate to form a pattern of energized light emittingdiodes indicating the extent of the selected parameter.